1

Evolution of Embraer Aircraft Design

EMB 120 Brasilia• 30 seat turboprop with pressurized fuselage • Maiden flight in 1983• Part 25 damage tolerant aircraft• Large advances in development of tools for DT analysis (development of in-house software, analysis of stiffened panels with two-bay cracks etc.)• Increase in the number of tests for materials and components

2

Evolution of Embraer Aircraft Design

EMB 120 Brasilia• FSTF for two lifetimes or 120,000 flights (fatigue)• Additional 15,000 FC (residual strength, crack propagation & tear down)

3

Evolution of Embraer Aircraft Design

ERJ 145 Family of Regional Jets• 50 seat twin-jet with fuselage cross-section similar to EMB 120 • Maiden flight of ERJ 145: 1995• Over 1,000 aircraft delivered (ERJ 135/140/145/145XR, Legacy)• 11,000,000 Flights completed in 2007 with Zero Accident• Part 25 damage tolerant aircraft• Further advances in fatigue and DT tests for sub-components (joints, mounts, etc.)

4

Evolution of Embraer Aircraft Design

ERJ 145 Family of Regional Jets

• FSTF for two lifetimes or 120,000 flights (fatigue)• 1 additional lifetime (residual strength and crack propagation)• Test finished in 2003

5

Embraer 170/190 – Fatigue & DT Tests

EMBRAER 190 – HS Fatigue Test• Performed for two life times - or 160,000 flights - started in 2003• 1 additional lifetime (residual strength and crack propagation)• Test finished in 2006.

Outline of Test Specimen

6

Embraer 170/190 – Fatigue & DT Tests

•Embraer-190 HS fatigue test third life: 160,000 to 240,000 flight cycles

• Location: HS “Middle spar near center line splice”

• Damage inserted in order to correlate theoretical prediction aproaches

• Induced artificial damage: middle spar failed and associated secondary crack in the upper skin

EMBRAER 190 – HS Fatigue Test

7

Embraer 170/190 – Fatigue & DT Tests

EMBRAER 190 – HS Fatigue Test

• Embraer-190 HS fatigue test third life: 160,000 to 240,000 flight cycles

• Verification of damage growth for critical region: from 55 mm (previous) up to 80 mm

8

Embraer 170/190 – Fatigue & DT Tests

EMBRAER 170/190 Family of Jets - FSFT

• Embraer 170 FSTF for 2 lifetimes - or 160,000 flights - started in 2002

9

EMBRAER 170/190 Family of Jets - FSFT

• Embraer 190 FSTF for 2 life times - or 160,000 flights - started in 2003• Forward and rear fuselage not included (common with Embraer 170)

Embraer 170/190 – Fatigue & DT Tests

10

Embraer 170 Fuselage Barrel Fatigue Test

Outline of Test Specimen

11

X X

Frm-03 Frm-04 Frm-05 Frm-07 Frm-06

Str-03R

Str-02L

Str-01L

Str-01R

Str-02R

Str-04R 12.712.7

Section X-X

Sheet Frame 05 and Shear

Clip Failed

Skin Crack

B-D01-2

DAMAGE B-D01-2 LONGITUDINAL SKIN CRACK WITH BROKEN FRAME IN TOP SKIN REGION

Embraer 170 Fuselage Barrel Fatigue Test

12

(a): Global FEM (Super element);(b): Residual Structure.

(a): Global FEM (Super element);(b): Residual Structure.

Embraer 170 Fuselage Barrel Fatigue Test

DAMAGE B-D01-2 – FEM Modelling Scheme

13

Embraer 170 Fuselage Barrel Fatigue Test

Longitudinal Skin Crack with Broken Frame in Top Skin RegionDamage B-D01-2

20

25

30

35

40

45

50

55

60

0 5000 10000 15000 20000 25000 30000 35000 40000

Flight Cycles (FC)

Hal

cra

ck s

ize

(mm

)

Test Results

DTD + Bulging Equation

Non Linear Analysis